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Pdca Problem Solving Guide
Pdca Problem Solving Guide
Pdca Problem Solving Guide
PL
T
I NVESTI GATE
AN
AC
CORRECT &
STANDARDI SE CLARIFY OBJECTIVES
SOLUTI ONS
EC
D
K
AN
AC
CORRECT &
STANDARDI SE CLARIFY OBJECTIVES
O
SOLUTI ONS
EC
D
K
AN
AC
CORRECT &
STANDARDI SE CLARIFY OBJECTIVES
O
SOLUTI ONS
EC
D
K
Customer
Satisfaction
CHECK DO
PL
T
I NVESTI GATE
AN
AC
CORRECT &
STANDARDI SE CLARIFY OBJECTIVES
SOLUTI ONS
EC
D
K
Purpose:- To
PL
A
CT
INVESTIGATE the
I NVESTI GATE
CORRECT &
A
STANDARDI SE DETERMI NE NEEDS
N
ں REVI EW FEEDBACK & ں DI AGNOSTI C:
CONTRI BUTI ON OF
OTHERS.
O
EC
D
solved.
K
Key Steps:-
Diagnostic - Review Current Practice.
Define the Problem - Who,What,Where and When .
Write Team Mission statement.
Brainstorm where else may they have this problem, find out
what they do to resolve it.
Purpose:- To
PL
CT I NVESTI GATE
A
CORRECT &
N
A
Enlighten the
STANDARDI SE DETERMI NE NEEDS
ط
RESPONSI BI LI TI ES:
WHY, WHAT & HOW
RECOGNI TI ON.
RECOGNI SE THE
analysing the
Data and defining
CH
CONTRI BUTI ON OF
OTHERS.
O
EC
K
D
and
implementing a
solution plan.
Key Steps :-
Enlighten
Brainstorm solutions.
Rank solutions to identify best impact.
Carry out Failure Prevention Analysis.
Carry out Solution Effect Analysis.
Create Project Plan to implement solutions.
Put measures of performance in place using
Control Charts or Check Sheets.
Implement
Carry out Project Plan.
Educate, train & communicate
Purpose:- To
PL
monitor effect of
CT
I NVESTI GATE
A
CORRECT &
N
A
STANDARDI SE DETERMI NE NEEDS
CH
ں FEEDBACK
ط RECOGNI TI ON.
O
OTHERS.
EC
D
K
Key Steps :-
Evaluate
Validate
CT
PL
I NVESTI GATE
A
CORRECT &
N
Performance Measure STANDARDI SE DETERMI NE NEEDS
A
ں REVI EW FEEDBACK & ں DI AGNOSTI C:
MAKE CORRECTI ONS طREVI EW CURRENT
BENCHMARKI NG:
طSUMMARI SE AND
required. Integrate new EVALUATE & VALI DATE ENLI GHTEN &
COMPARE BEST
PRACTI CES.
ط
WHY, WHAT & HOW
RECOGNI TI ON.
RECOGNI SE THE
CH
CONTRI BUTI ON OF
OTHERS.
O
EC
D
K
Key Actions :-
Correct & Standardise
Decide if solution is effective & either integrate into
normal working practice or abandon. If plan is
abandoned, ask what has been learned by the
process and, restart the project.
AN
AC
CORRECT &
STANDARDI SE CLARIFY OBJECTIVES
CHECK DO TRAINING
UNDERSTAND HOW
PROBLEM OCCURS
CH
COMMUNICATION I DENTI FY POSSI BLE
O
SOLUTI ONS
EC
D
K
Checklist of PDCA Approach :
Have you got:
a Sponsor - ( Person who instigates the Problem Solving Session )
b Team Leader.
c Facilitator
d Team Members
Customer
Satisfaction
Techniques to use with PDCA -
DO
Selection Chart
CHECK
Technique P D C A
1 BRAINSTORMING ü ü ü ü
2 CAUSE & EFFECT ü ü
3 CHECK SHEETS ü ü ü
4 PARETO ANALYSIS ü ü ü
5 CONCENTRATION DIAGRAMS ü ü ü
6 PROCESS FLOW CHARTS. ü ü
7 PERFORMANCE MEASURING ü ü ü ü
8 5 WHY'S & 5W1H ü
9 PAIRED COMPARISONS ü ü
10 IMPACT DIAGRAMS ü ü
11 FORCE FIELD ANALYSIS ü
12 SOLUTION EFFECT DIAGRAM ü
13 SCHEDULE or PROJECT PLAN ü
14 FAILURE PREVENTION ANALYSIS
ü
ACT
PLAN
Customer
Defining the Problem in
Satisfaction
CHECK DO
SMART form.
What is this ? It is the first step in the PDCA
problem solving cycle.
How de we do it ?
CHECK DO form.
Customer
The Quick Fix
Satisfaction
CHECK DO
How do we do this ?
They are usually, but not always, Time Consuming and Expensive.
If , for example, the problem was a “ leaking roof due to a cracked tile “
The quick fix could be
To put a bucket under the leak.
The final solution could be
Replace the Tile, Check condition of other tiles annually.
ACT PLAN
Customer
Satisfaction
Technique 1 - BRAINSTORMING
CHECK DO
STEP 3
ü As a Team discuss each idea and decide if t hey ar e Tot ally, Part ially or
Not in t he Cont r ol of t he Team.
ü Separ at e out t he "Tot ally" ideas.
ü Pr ior it ise t hem using " I mpact Diagrams" or "Paired Comparisons".
STEP 4
Customer
Satisfaction Technique 2 - CAUSE & EFFECT
CHECK DO
What is it ? - I t is a met hod of Brainst orming Causes of a pr oblem or sit uat ion.
Why do it ? - To help t he Team can f ocus on specif ic t hemes and gr oups of causes .
Where is it used ? - I n t he t eam r oom or at place of wor k
When do we use it ? - When a pr oblem or ef f ect is def ined and possible causes ar e
needed.
Who uses it ? - Ever yone.
How do we use t hem ? -
St ep 1 - On a lar ge boar d or f lip char t . Const r uct t he diagr am below.
MAN MACHINE
MATERIAL METHOD
St ep 2 - A Scr ibe Will t ake POSSI BLE CAUSES f r om r ound t he t able in Tur n unt il
Dr ied up. As per example below.
MEN Machines
Operator not Trained Machine not Capable
Machine Gauging Faulty
St ep 3 - Priorit ise and Select t hose t o be invest igat ed, by allocat ing VOTES t o each
Team member who add t heir choices t o t he Diagr am . As per Diagr am Below.
MEN Machines 3
Operator not Trained Machine not Capable
5 1
8
ACT PLAN
Customer
Satisfaction
Technique 3 - CHECKSHEETS
CHECK DO
Customer
Technique 4 - PARETO ANALYSIS
Satisfaction
CHECK DO
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90
80
70
60
50
40
30
20
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ACT PLAN
Customer
Satisfaction
Technique 5 - CONCENTRATION
CHECK DO
DIAGRAMS
How do we use it ? -
Customer
Satisfaction
Technique 6 - PROCESS FLOW
CHECK DO
CHARTS.
How do we use it ? -
The example below shows PDCA in a Flow Char t f or m.
Make an
Implementation Set up Measures to REVIEW EFFECT on
Monitor the Effect. IMPLEMENT MEASURES - MAKE
Schedule using Use Checksheets,
COUNTERMEASURES to
PROJECT PLAN ENSURE OBJECTIVE
Technique 13 - Project Paretos, Control Charts. IS ACHIEVED.
Planning
ACT PLAN
Customer
Technique 7 - Measuring
Satisfaction
CHECK DO
Performance.
What is it? - It is a way of showing the Results and effects of changes made
to a process.
Why use it? - To understand the current performance and to chart
improvements and progress towards a target.
Where is it used? - Usually at the place of work or on the process being
monitored.
When is it used ? - From the start of a project right , through to the end.
Data is usually added every day , week or month.
Who uses it ? - The Team.
How is it used ? -
30000 110%
25000 100%
20000 90%
15000 80%
10000 70%
5000 60%
0 50%
1994 1995 1996 1997 JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC
ACT PLAN
Customer
Satisfaction
Technique 8 - a) 5 WHY’s b) 5W1H.
CHECK DO
Customer
Satisfaction
Technique 9 - Paired Comparisons.
CHECK DO
What are t hey ? - They ar e a met hod of Helping t he t eam pr ior ot ise a
number of pot ent ial causes and solut ions.
Customer
Satisfaction
Technique 10 - IMPACT DIAGRAMS.
CHECK DO
What are they? - They are a method by which the Team can identify the
priorities of a large list of Ideas/actions or Causes...
Why use them? -To get a Team Consensus and get the greatest Impact with
least effort.
When is it used? - In cases where the is a long list of items.
Where is it used? - Team Meetings
How is it done? -
Step1 Each Team Member should Rank against 2 - Criteria
1 The EASE of achieving ( 1 = Very Difficult to 10 = Very Easy ), and
2 The IMPACT of the result ( 1 = Very Low to 10 = Very High ) on the problem.
1 Training 9 6
2 New Gauge 5 9
3 New Machine 2 9
4 Change Coolant Supplier 4 4
5 Change Coolant Mix 8 4
6 In Process gauge 5 7
7 Air Plug on Line 8 9
8 SOP 9 9
9 100% checking by hand 8 8 These items
10 Communication 9 6
should be
done first as
HIGH
10 High
Impact /
10 8
9 3 2
8
Easy to do
IMPACT
9
7 6
6 10
&1
5
4 4 5
3
2
1
LOW 0
0 2 4 6 8 10
VERY VERY
EASE EASY
DIFFICULT
ACT PLAN
Customer
Satisfaction
Technique 11 - FORCE FIELD
CHECK DO DIAGRAMS.
What are t hey ? - A met hod of considering t he posit ive and negat ive ef f ect s of implement ing
solut ion,
Why use t hem ? - To evaluat e t he possibilit ies of addit ional out comes t o t he proposed
solut ion.
How is it used ? -
St ep 1 Writ e at t he t op of a f lip chart t he solut ion being discussed t hen draw diagram below.
Customer
Satisfaction
Technique 12 - SOLUTION EFFECT
CHECK DO DIAGRAMS
What is it? - It is a way of Brainstorming the consequences of
implementing a solution..
Why use it? -The Team should be aware of any side effects that
implementing a solution may have.
When is it used? - When a solution has been determined , but prior to
implementation.
Where is it used? - Team Meetings
How is it done? -
- 1 Construct the Diagram Below
MONEY MATERIALS
Addit ional
Wages Admin Improved JIT
Cost supply to Customer
Incr eased
Power use
Implement 3 - Shift
Working Improved Manning Additional Skills
Flexibility
Improved Setting
Improved
Morale
METHODS MANPOWER
Customer
Satisfaction
Technique 13 - SCHEDULE or
CHECK DO PROJECT PLANNING.
Customer
Satisfaction
Technique 14 - FAILURE
CHECK DO PREVENTION ANALYSIS.
Overall
Potential Failure Potential Consequence Ranking
Rating
Score Potential and Consequence on a scale of 1 to 10 and multiply together to give overall Rating